Fused glass sheets having ceramic paint and metal foil and method of making same

Abstract

The invention is a composite glass sheet and method of making same. In detail, the composite glass sheet includes first and second translucent ceramic layers, having one principle side coated with ceramic paint, and a sheet of metal foil positioned between the coated sides with the whole assembly fused together. The method includes the steps of: providing first and second sheets of translucent glass having first and second principle sides; coating at least a portion of the first principle sides of the first and second sheets with a layer of ceramic paint; providing a sheet of metal foil between the coated first principle surfaces forming an assembly; and heating the assembly to a sufficient temperature for a sufficient time such that the first and second coated sheets of glass and the metal foil are all fused together.

I claim: 
     
       1. A composite glass sheet comprising: first and second translucent glass sheets, said first and second translucent glass sheets having outer facing first principle sides and second principle sides facing toward each other, each of said translucent glass sheets having a peripheral edge,   a layer of metal foil in the form of a sheet having opposed principle sides positioned between said second principle sides of said first and second translucent glass sheets within the peripheral edges of said first and second translucent glass sheets; and   first and second layers of ceramic paint extending over at least a portion of the second principle sides of said translucent glass sheets and said opposed principle sides of said metal foil,   said second principle sides of said first and second translucent glass sheets and said first and second layers of ceramic paint fused together wherever in contact with each other and said opposed principle surfaces of said metal foil bonded to second principle sides of said first and second translucent glass sheets and said first and second layers of ceramic paint fused together wherever in contact with each other.   
     
     
       2. The composite glass sheet as set forth in claim 1 wherein the metal foil has a smaller cross-sectional area than said first and second glass sheets. 
     
     
       3. The composite glass sheet as set forth in claim 2 wherein said metal foil is selected from the group consisting of copper, brass, lead, steel, zinc, titanium, silver, gold and platinum. 
     
     
       4. The composite glass sheet as set forth in claim 3 herein at least one of said first and second layers of ceramic paint contain include pigmentation. 
     
     
       5. The composite glass sheet as set forth in claim 4 wherein the thickness of said metal foil is between 0.0001 to 0.015 inch thick. 
     
     
       6. The composite glass sheet as set forth in claim 5 wherein the thickness of said metal foil is between 0.0001 and 0.006 inch thick. 
     
     
       7. The composite glass sheet as set forth in claim 5, or 6 wherein said ceramic paints comprise glass frits, pigments and a carrier and said pigments are metal oxides selected from the group consisting of zinc, aluminum, tin, antimony, cadmium, chromium, lead, cobalt, copper, manganese, iron, silicon, titanium, tungsten, and bismuth oxide. 
     
     
       8. The composite glass sheet as set forth in claim 7 comprising said glass frits consisting of the group lead borosilcate and soda-lime borosilicate. 
     
     
       9. The composite glass sheet as set forth in claim 8 wherein the concentration of said metal oxide powders is between 1 and 30 percent. 
     
     
       10. The composite glass sheet as set forth in claim 9 wherein the concentration of frits is between 30 to 50 percent. 
     
     
       11. The composite glass sheet as set forth in claim 10 wherein the thickness of said first and second translucent glass sheets is between 0.03 inch to 2.0 inches. 
     
     
       12. The composite glass sheet as set forth in claim 11 wherein at least one of said second principle sides of said first and second translucent glass sheets are textured. 
     
     
       13. A method of making a composite glass sheet comprising the steps of: providing first and second sheets of translucent glass having first and second principle sides   providing a layer of metal foil having first and second principle surfaces;   coating at least a portion of said first principle sides of said first and second sheets with a layer of ceramic paint;   placing said first and second sheets of coated translucent glass on to said first and second sides of said metal foil such that said coated first sides thereof are in contact with said metal foil; forming an assembly; and   heating said assembly to a sufficient temperature for a sufficient time such that said first and second coated sheets of glass and said metal foil are fused together.   
     
     
       14. The method as set forth in claim 13 wherein the cross-sectional area of said metal foil is less than the cross-sectional area of said first and second glass sheets. 
     
     
       15. The method as set forth in claim 14 wherein said metal foil is selected from the group consisting of copper, brass, lead, steel, zinc, titanium, silver, gold and platinum. 
     
     
       16. The method as set forth in claim 14 wherein at least one of said first and second layers of ceramic paint contain include pigmentation. 
     
     
       17. The method as set forth in claim 16 wherein the thickness of said metal foil is between 0.0001 to 0.015 inch thick. 
     
     
       18. The method as set forth in claim 17 wherein the thickness of said metal foil is between 0.0001 and 0.006 inch thick. 
     
     
       19. The method as set forth in claim 18, wherein said ceramic paints include metal powders selected from the group consisting of zinc, aluminum, tin, antimony, cadmium, chromium, lead, cobalt, copper, manganese, iron, silicon, titanium, tungsten, and bismuth. 
     
     
       20. The method as set forth in claim 16 wherein the concentration of said metal powder is between 1 and 40 percent. 
     
     
       21. The method as set forth in claim 20 wherein the thickness of said first and second glass sheets is between 0.03 inch to 2.0 inches. 
     
     
       22. The method as set forth in claim 21 wherein said second principle sides of said first and second glass sheets are textured.